Adjustable tip for resistance welding electrodes



Aug. 16, 1949- c. F. WERSLER ET AL 2,479,547

ADJUSTABLE TIP FOR RESISTANCE WELDING ELECTRODES Filed Ooi. 2, 1946 i yZI. i fi l V/ x rn o n www@ A TTORNE Y Patented Aug. 16, 1949 UNITED STAT iis-SENT OFFICE ADJUSTABLE TIP FOR RESISTANCE WELDING ELECTRODES Sylvania Application October 2, 1946, Serial No. 700,778

(Cl. 21S-4) 3 Claims.

This invention relates to welding electrodes for resistance Welders.

In welding operations where welds are being applied to metal sheets having a finished surface, the problem arises of preventing the finished surface from being marred by the mechanical pressure between the electrodes, as Well as by the high temperatures which are involved in the welding operation.

It is a primary object of the present invention to provide an electrode which may be utilized in resistance welding Without marring the finished surface of the workpiece to which the Weld is applied.

Another object of the invention is to provide an electrode which distributes the pressure of the electrode over a substantial surface around the weld point, tending to prevent indentation of the workpiece in the areas external to the Weld.

Another object of the invention is to provide an electrode Which reduces the density of electrical current utilized in the welding operation at the finished surface of the workpiece sheet or plate so as to reduce marring of the finish from overheating.

Still another object of the invention is to provide an electrode having a tip which automatically adjusts itself to the workpiece surface.

An object of the invention also is to provide an electrode With a modified universal joint, with accessory means for preventing oxidation of the joint surfaces and resulting electrical ineiiciency.

A related object is to provide an electrode tip having direct cooling means for reducing the heat transfer to the electrode holder.

Referring to the drawings:

' Figure 1 is a view of one form of the electrodes for accomplishing the objects of the invention;

Figure 2 is a view of a modification of the electrodes, with parts in section; and

Figure 3 is a detail showing the joint connection of the modiiication of Figure 2.

In Figure 1 the upper electrode is indicated by the numeral I and is formed of a holder 2 and a tip 3, with a joining connection including the `ball coupling 4 and socket coupling 5. The holder 2 is tubular in construction to permit passage of coolant, The ball coupling 4 consisting of a ball head 6 and a shaft I is also tubular, and when the shaft 'I is inserted in the hollow end of the holder 2 coolant may penetrate within the ball coupling to the interior of the ball 6. An inner supply tube 2' is provided Within tube 2 as is usual.

The socket coupling 5 includes the shell 8 provided with a recess 9 having a spherical surface for cooperative engagement with the ball 6 of the ball coupling il. The throat of the recess is sufficiently large to permit insertion of a threaded sleeve IU with space between the sleeve and shaft 'i for limited universal movement of the shaft. The inner diameter of the sleeve I0 is less than that of the ball 6 to hold the ball in place in the socket.

The electrode tip 3 is formed of two flat plates ii and I2 welded together and attached to the socket shell in extension of and transversely to the holder axis. Plate II is shown integral with the socket shell, anad plate I2 is Welded to plate il. Plate II', socket shell 8 and holder 2 are preferably of copper, while plate I2 is of alloy, such as that of copper and nickel, capable of withstanding the high temperatures and pressures involved in resistance welding. The tip plates may be circular or of any desired shape.

Coolant is supplied directly to the tip from a. drum I3 and iiexible conduits I4 and I5. Atransverse aperture I6 is formed through the plate II oi the tip, and at the end openings couplings I'I and I8 are attached to which the conduits I4 and I5 are connected. A steady flow of coolant is maintained through the tip aperture during welding operations. Coolant is also passed through the holder 2 and ball coupling 4, as previously indicated.

Cooperating with the electrode I and positioned axially in extension thereof for cooperative action on the workpiece plates I9 and 20 is the lower electrode 2i. The nugget 22 between the electrodes at the interface between the workpiece plates is indicative of the type of Weld secured by theY electrodes.

From the above description it is apparent that a limited universal connection is provided between the holder 2 and the tip 3 so that the tip may accommodate itself to a limited extent in any direction of pressure to the surface of the workpiece. Accordingly, on account of the enlarged surface of the tip which bears on the workpiece, pressure on the workpiece is equalized and the current density at the contacting surface with the tip is diminished to a point where injury to the finish is eliminated. In addition, it is now clear that the coolant penetrating the aperture i6 in the tip is made effective on the bearing surfaces of the ball aand socket joint so that oxidation on these surfaces is prevented, with consequent maintenance of high electrical conduction and eiiiciency. The presence of the coolant in the tip also prevents overheating of the alloy plate l'2 in cooperation with the extended area of contact, thus aiding in the prevention of mar to the nished surface of the workpiece.

The modification of Figure 1 is useful particularly where pressuresare vertical. In Figures 2 and 3 we'have shown a modification which is eiiciently usable not only in a vertical position,. but in horizontal and other positions. In this form of the invention the uppen electrode 3llinscludes a holder 3|, a tip member 32, andla' cou-- pling member 33. The holder 3|- is-tubular. and

has an inner supply tube. 3.|- similartoA the..

holder 2 of Figure 1. The tipw32sof-,themodification is provided with a special alloy contact plate 34, similar to the plate I2 of Figure 1. The tip element 35, however, includes-a coolant coupling connection 36 extending at an angle onloneisideof thetip member 35. This coupling is hollow, as.at.3.1, for.. entrance ofthe coolantand is interorly screw threaded adjacent the end thereof toreceive a flexiblehose connector (not shown) for. removal. of. coolant. Supply of coolant is by means. of thetube 38.which.penetrates .the cavity 3`I.in.the,coupling.36,.anouter tube 38,' connected to.a..nipple 35 carryingcoolant away.

Connection between the electrodey holderl 3l and the..tip. element. 35 is..by means of the coupling member 33. This member includes a-ball lllconnectedto theholder :il-by` ahollow shaft 4|.;,andzasocket 42having. a.curved.recess corresponding.infcurvaturetoL the ball surface. VA pin43is-xed tothe socket-seas toextend trans'- versely, acrossthe recess, andthispin is adapted tov lgienetrai'cfanfaperturelillI formed transversely in. the.' coupling. ball 401.- The.. aperture diameter isl infexcess of that-of. thepin 43, as'shown in FiguresZ and3,I` sol that a limitedipivotal movement. between. ball and. socket ispermitted in the plane-includingthe. pin and holder. Atright angleszto=this plane the ball may move to the limit. of= thesocket recess wall. Inthis manner a :limited universal. connection between the ball andisocket is obtained.

The. modicationof Figures 2 and 3 has'been foundto. be. particularly-useful in applying welds to. surfaces. at, any. angle4 ofv engagement. Inspection ofrthese Figures makes clearthat the bearingY surfaceof the balland socket joint isgeometrically centered in the tip, andV consequently itwould be expected that itis approximately, at' the. centen of mass.` Because of this positional relationship,` when the tube is held with the holder. horizontal, for example,.and applied againsty averti'caLworkpiece, the tendency oftliet-ip toY pivoton the joint. is veryl substantially reduced, ifnot eliminated. This isimportant for welding operations on vertical workpieces sinceY if the. pivot point=is moved from the center. of 'mass ofthe tip to a point where horizontalholding of the electrode willcause pivoting of'tlie tip with the` upper. edge. leading, on pressure of, the electrode against the workpiece this upper edge will engage the workpiece Vand gouge the surface thusdestroying the appearance of the nish and moreover tendingto bend the upper electrode out of' alignment with the lower electroderesulting.in inferior welds. The electrode arrangement, of Figure 1 maynotsatisfactorily beused for vertical operations on. accountof thispivoting, action. Placement of. the coolant cou-- pling` connection 36.' at an anglewiththe bearing: surface ofthe tipwitha substantial` mass thereof.- oifcenter also contributesto maintenance of thee bearing surface of the tip in a substantially vertical plane transverse to the axis of the electrode holder.

In addition, the effective cooling of the tip wherein the heat withdrawal from the tip is directly through the solid metalto'the coolant insures maintenance of low temperature at the coupling surfaces so that, in conjunction with the cooling of the electrode holder 3l and the oupling 33, oxidation of the coupling surfa es, with resultant early destruction of electrode usefulness, is prevented.

Exemplary forms of the invention have been described, but it is apparent that modifications may be madeI to t specific needs, the scope of the invention being determined by the claims as hereto' appended.'

What is claimed is:

1. An electrode -for resistance welding apparatuscomprising.,aW tubular holder', atip having a workpiece-engaging surface and-a coolant .coupling, and coupling means` for. establishing a universal jointbetween the holder, and-tip; said couplingmeans comprising a shaft xeditofsaid holder,A a. curved head. xed. to said;v shaft and adapted to engage a recess formed insaidy tip having a cooperating. interior: surface curvature, an aperture formed through said headlatrig-,ht angles to the holder axis, and..a.pin.xed to-'fthe tip and penetrating said head.. aperture, the-di ameter. of the headapertureV being greater than thatA ofjthe. pin.

2. An electrode for resistance welding: appairatus vcomprisingafholder, a tip. having. aaworkpiece-engaging. surface, and: coupling means for establishing a universal jointv betweencooperating parts ofthe holder. andtip, said. coupling means comprising. ay ball onone parthavinga transverse opening. therethrough, a;` socketonthe other part adapted to receive said.- ballandz a pivot pin supported: by.' the part having said socket, said p in passing` through said-,ball opening, said opening having a-transverseareaflarger than that of the pin whereby limited universal relative movementA of the ball and-,socketparts CLARENCEJ?. WERSLER-; JOSEPH BUKOWSKI;

REFERENCES CITED.

Thefollowing references are of record? in1t'he file 'of this patent:

UNITED STATES'PATENTSY Number Name Date 935,346 Wineld Sept; 28.511909.1 1,861,970 Meadowcroft June 7, 1932. 1,992,990- Burns Mar;;.5, 1935i 2,179,693 Goldstein .Nov. 143.19397 2,260,866 PowellI Oct. 283 2,315,854 Holt: Apr: 6,,19431 2,346,088 Shobert Apr. 4,1944; 

